TOOLMASTER G198 TOOL & CUTTER GRINDER MANUAL

1 PREFACE

This manual is the operation and maintenance instructions of the G198 Toolmaster tool and cutter grinder. Please put this manual in a place where the operator can easily find it for quick reference The operator should fully understand the instructions in this man- ual so that trouble free continuous operation can be obtained.

All the drawings and pictures in this manual are only used for description. Dimension, accuracy or other details are given for an example. According to our continuous improvements and our product policy, we reserve the right to change the machine speci- fications and designs without notice, Our machine and accessories are covered for 12 months against any materials or manufacturing defect. .lf the defect is due to abnormal operation or misunder- standing operation methods, then it is beyond this guarantee.

Upon receiving the G198 machine, please check all the parts and accessories according to packing list. If there are any shortages or damage, please report to us immediately. If there is any complaint or service required, it must be accompanied with the machine se- rial number.

2 CONTENT

1. Location and Lifting

1-1 Location 1-2 Lifting

2. Main Structure Introduction 3. General Specification

3-1 Dimensional drawing 3-2 Main Specification 3-3 Design feature

4. Operating Instruction

4-1 Mounting 4-2 Wheel Dressing : 4-3 Cutting Tool Instruction 4-4 Basic setting for the cutter grinding 4-5 End Cutter Outer Flute 4-6 Cutter End Side Grinding

5. Dividing Attachment

6. Sharpener

7. Parts List

3 1.Location and Lifting

1-1 Location It Is recommended to locate this machine if possible in a position with constant tem¬perature (about 20 °C) and is not recommended in a position that is damp, or near chemical gas or vibration. The machine should not be exposed to con- stant sunlight, rain, or operated in a potential explosive environment.

I -2 Lifting

The use of web slings is recommended. Move the saddle to the back position and lock the saddle before lifting. Remove the motorized workhead and restrict the table travel so that it cannot move. Lower the head and place a block of wood between the head and the table to insure that the table does not lift during lifting Use the lifting web slings for lifting as below, with one sling under the cross slide and the other around the column. Adjust the slings until the machine is level. (the net weight of machine is 212kg)

Cautions when lifting: (1) Lift the machine with the slowest speed of crane. (2) Retaining the machine balance during the lifting Put the machine down carefully and slowly to the desired location. (3) During lifting, please insure that no one stands beneath machine. Keep people away from the dangerous zone at least two meters.

Block of wood

4 MAIN STRUCTURE INTRODUCTION

I. Elevating handwheel 2. Wheel head tilt clamp. 3. Super-Precision motor spindle assembly. 4. Vertical locking screw. 5. Wheel head setting lever. 6. Motorized workhead 7. Forward and reverse switchs. 8. Cross feed handwheel 9. Longitudinal handwheel 10. Table Taper adjustment 11. Tailstock 12. Work light 5 3. GENERAL SPECIFICATION

I, Parameters

1. Max. Grinding Diameter 250mm 2. Grinding Length 400mm 3. Lifting Height Of Grinding Wheel 150mm 4. Rotating Angle Of Grinding Wheel 360 °(Vertical/Horizontal) 5. Lateral Feeding Distance 190mm 6. Dimension Of Grinding Wheel (DxHxd) 150x50x32mm 7. Max. RPM of Grinding Wheel 5000rpm 8. Motor For Grinding Wheel 0,55KW(314HP) 220V/60HZ/3Hp 3600RPM 9. Motor For Head Folder 90watts 220V 1400rpm 10.Total Power 0.64Kw 11. Weight Of The Machine 222kg Gross Net 209kg 12. Dimensions of Machine (LxWxH) 870x730x810mm 13. Package Dimensions (LxWxH) 730x710x715mm

6 GENERAL SPECIFICATION

(1) 3-3 Designing Features

(2) Working table is mounted on a high precision linear ball slide to insure smooth operation.

(3) The motor can rotate 360 degrees

(4) Motorised work head can be used in either for- ward or reverse mode

(5) Precision acme screw thread to adjust the head 160mm up-down.

(6) The machine is manufactured from Fc30 Cast iron. (7) The column can adjust to 360 °

7 OPERATING INSTRUCTION

4-1 Mounting The Grinding Wheel:

A. If selecting a wheel not supplied with the machine, refer to a wheel speed chart to insure that the speed is correct for the wheel shape and size. (Please contact a grinding wheel dealer for this information).

B. Supplied is a Diamond wheel suitable for HSS and carbide grinding. We also recommend that you use a 5 “ flared cup, aluminum oxide, grinding wheel. The best grade is vitrified bonded 60 grit. Dress the wheel with a dressing stick. Dish the face about 10 °, and smooth the periphery and your wheel is ready to work.

C. Check grinding wheel to ensure the wheel is not cracked.

D. Never alter the bore of the grinding wheel or force a wheel into spindle.

E. Apply one clean, smooth blotter on each side of the wheel under each flange.

F. Stand away from the front and the back of the wheel when first starting the grinding wheel. Before commencing to grind, run the wheel for at least one minute to test the wheel.

G. Always store the grinding wheel at a dry and moderate temperature place.

H. Please follow the instruction of the mounting and dressing of the grind ing wheel in this manual.

1. Do not wear Rings, Wrist Watches, or Loose Long-Sleeve shirts when operating this machine.

8 4-2 Wheel Dressing

1. For an aluminium Oxide wheel you can use a dressing stick to manually dress the edge of the cup wheel with a sharp 10 ° angle. This should be done before using the machine,

2. The othe method is to use a diamond dresser to dress the wheel. The proce dures as below.

(1) Lower the wheelhead until the spindle center is slightly higher the diamond nib.

(2) Mount the dividing attachment on the table and insert the tool holder. Secure the diamond dresser usuing the clamp screws. Tilt the diamond to an angle of 85 degrees to the wheel to be dressed.

(3) Crossfeed the table until the diamond nib is within 1mm of the wheel. Start the spindle, and lower the head until you hear the diamond just touch the wheel. Traverse the table slowly across the wheel to dress it. NOTE! The down feed rate each time should not be over 0.001 “. Heavy cuts will dislodge the diamond. Dressing will allow the periphery of the wheel to be concentric to the spindle and will help balance the wheel and remove vibration.

(4) Re-sharpen the cutting surface of the grinding wheel frequently or when the finish is poor

9 4. OPERATING INSTRUCTION

4-3 Cutting Tool Instruction

10 4. OPERATING INSTRUCTION

4-4 Basic Setting for the Cutter Grinding

A .Sharpening High-Speed Steel And Cast Alloy Multi-Tooth Cutters

The working efficiency of a cutter is determined by the keenness of its cutting edges. When the cutting edges become dull, the cutter must be re-sharpened. A dull cutter will produce a poor finish surface. Frequently re-sharpen the cutter, and the cutter will be maintained in good working condition.

Regular re-sharpening the cutter, insures only a very small amount of material is taken of the teeth to restore its keen cutting edges. Cutters and are usually re-sharpened on the tool and cutter grinder using the accessories. The universal cutter grinder as its Name says, allows for various kind of tools, to be ground on this grinder.

a. Suggestion of the grinding wheels.

Usually a soft grade of grinding wheel is used to allow the free cutting action and avoid overheat being generated at the cutting edges. If the grinding wheel is t